Feeler Gauge

–

1

Caliper Gauge

–

1

Micrometer

–

1

Vernier Caliper

–

1

Engine Stand

–

1

SPECIAL SERVICE TOOLS (SST)

PART NUMBER

QTY

Gasket Seal Cutter

09032-00100

1

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

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February 13, 2015

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2AZ-FXE Oil Consumption

Repair Procedure
NOTE
Verify that Service Bulletin No. L-SB-0109-14, “2AZ-FXE Engine Oil Consumption Inspection
Procedure,” has been performed BEFORE continuing with this bulletin.

Replace the piston and piston ring set.
1. Remove the engine assembly and place on an engine stand.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:
• 2010 / 2011 / 2012 HS 250h:
Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical:
Engine Assembly: Removal”
2. Remove the cylinder head assembly.
Refer to TIS, applicable model and model year Repair Manual:
• 2010 / 2011 / 2012 HS 250h:
Engine/Hybrid System – Engine Mechanical – “2AZ-FXE Engine Mechanical:
Cylinder Head Gasket: Removal”
3. Remove the pistons from the connecting rods.
A. Remove the oil pan drain plug and gasket.

Figure 1.

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

Rev2

February 13, 2015

2AZ-FXE Oil Consumption

Repair Procedure (Continued)

B. Remove the oil pan sub-assembly.
(1) Remove the 12 bolts and 2 nuts.

Figure 2.

(2) Insert the blade of the Gasket Seal Cutter
between the crankcase and oil pan.
Cut through the sealer and remove the
oil pan.

Figure 3.

SST: 09032-00100
NOTICE
Be careful NOT to damage the contact
surfaces of the crankcase, chain
cover, and oil pan.

1

C. Remove the oil pump assembly by removing
the 3 bolts and gasket.

Gasket Seal Cutter

Figure 4.

© 2016 Lexus, a division of Toyota Motor Sales, USA

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2AZ-FXE Oil Consumption

Repair Procedure (Continued)

D. Remove the engine rear oil seal.

Figure 5.

(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver (with a taped tip),
pry out the oil seal.
NOTICE
After removing the oil seal, check
the crankshaft for damage. If the
crankshaft is damaged, smooth the
surface with 400-grit sandpaper.

1

Cut Position

E. Remove the stiffening crankcase assembly.
NOTICE
Remove the stiffening crankcase as a unit. Do NOT separate the halves of the assembly,
exposing the balance shaft bearings.

(1) Uniformly loosen and remove the 11 bolts
in the sequence shown in the illustration.

Figure 6.

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

Rev2

February 13, 2015

2AZ-FXE Oil Consumption

Repair Procedure (Continued)

(2) Using a screwdriver (with a taped tip),
remove the crankcase by prying between
the crankcase and cylinder block.

Figure 7.

NOTICE
Be careful NOT to damage the
contact surfaces of the crankcase and
cylinder block.

1

(3) Remove the O-ring from the
cylinder block.

Protective Tape

Figure 8.

© 2016 Lexus, a division of Toyota Motor Sales, USA

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2AZ-FXE Oil Consumption

Repair Procedure (Continued)

F. Remove the piston sub-assemblies with connecting rod.
(1) Using a ridge reamer, remove all the
carbon from the top of the cylinder.

Figure 9.

(2) Check that the matchmarks on the
connecting rod and cap are aligned to
ensure correct reassembly.

Figure 10.

HINT
The matchmarks on the connecting
rods and caps are provided for
ensuring correct reassembly.

1

(3) Using a 12 mm socket wrench, uniformly
loosen the 2 bolts.

Matchmark

Figure 11.

© 2016 Lexus, a division of Toyota Motor Sales, USA

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2AZ-FXE Oil Consumption

Repair Procedure (Continued)

(4) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and
lower bearing by moving the connecting rod cap right and left.
HINT
Keep the lower bearing inserted in the connecting rod cap.

(5) Inspect the connecting rod oil clearance.
1. Clean the crank pin and bearing.
2. Check the crank pin and bearing for pitting and scratches.
3. Lay a strip of Plastigage™ on the crank pin.
Figure 12.

1

Plastigage™

4. Check that the front mark of the connecting rod cap is facing forward.
Figure 13.

1

Front Mark

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

Rev2

February 13, 2015

Page 11 of 23

2AZ-FXE Oil Consumption

Repair Procedure (Continued)

5. Install and alternately tighten the bolts of the connecting rod cap in several steps.
Figure 14.

Torque: 25 N*m (250 kgf*cm, 18 ft*lbf)
NOTE
The connecting cap bolts should be tightened in 2 progressive steps.

6. Mark the front of the connecting rod cap bolts with paint.
Retighten the cap bolts by 90◦ as shown in the illustration.
Figure 15.

1

Paint Mark

2

90◦

3

Engine Front

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

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February 13, 2015

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2AZ-FXE Oil Consumption

Repair Procedure (Continued)

7. Remove the 2 bolts and connecting rod cap.
8. Measure the Plastigage™ at its widest point.
Standard Oil Clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.)
Maximum Oil Clearance: 0.08 mm (0.0032 in.)

If the oil clearance is greater than the maximum, replace the connecting rod
bearings. If necessary, inspect the crankshaft.
NOTE
Completely remove the Plastigage™ after the measurement.

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

Rev2

February 13, 2015

2AZ-FXE Oil Consumption

Repair Procedure (Continued)
HINT
If replacing a bearing, replace it with
one that has the same number as
its respective connecting rod cap.
Each bearing’s standard thickness is
indicated by a 1, 2, or 3 mark on its
surface.

Figure 16.

Standard Connecting Rod Large End
Bore Diameter:
MARK

SPECIFIED CONDITION

Mark 1

51.000 to 51.007 mm
(2.0079 to 2.0082 in.)

Mark 2

51.008 to 51.013 mm
(2.0082 to 2.0084 in.)

Mark 3

51.014 to 51.020 mm
(2.0084 to 2.0087 in.)

Standard Connecting Rod Bearing
Thickness:
MARK

SPECIFIED CONDITION

Mark 1

1.485 to 1.488 mm
(0.0585 to 0.0586 in.)

Mark 2

1.489 to 1.491 mm
(0.0586 to 0.0587 in.)

Mark 3

1.492 to 1.494 mm
(0.0587 to 0.0588 in.)

1

Plastigage™

2

1, 2, or 3 Mark

Standard Crankshaft Pin
Diameter:
MARK

SPECIFIED CONDITION

Mark 1
Mark 2

47.990 to 48.000
(1.8894 to 1.8898 in.)

Mark 3

© 2016 Lexus, a division of Toyota Motor Sales, USA

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2AZ-FXE Oil Consumption

Repair Procedure (Continued)

(6) Push the piston, connecting rod assembly, and upper bearing through the top of the
cylinder block.
HINT
• Keep the bearing, connecting rod, and cap together.
• Arrange the piston and connecting rod assemblies in the correct order.

(7) Repeat for the other 3 piston/connecting rod assemblies.
G. Remove the connecting rod bearings.
HINT
Arrange the removed parts in the correct order.

H. Inspect the cylinder bore for abnormal damage.
Visually check the cylinder bore for the presence of crosshatch.
• If the cylinder bore has visible crosshatch, the cylinder block is OK to re-use.
• Confirm that only light vertical marks are present, if any.
NOTE
• It is normal for an in-service block to have light markings present from carbon and
should NOT be interpreted as excessive cylinder wall scratches.
• ONLY replace the short block if multiple, severe scratches are present.
• Do NOT hone the cylinder walls.

I. Using a screwdriver, pry out the 2 piston pin
hole snap rings.

Figure 17.

HINT
If necessary, sublet the following
specialized and precision operations to a
local engine machining shop.

© 2016 Lexus, a division of Toyota Motor Sales, USA

L-SB-0006-15

Rev2

February 13, 2015

Page 15 of 23

2AZ-FXE Oil Consumption

Repair Procedure (Continued)

J. Remove the piston.
(1) Gradually heat the piston to
approximately 176◦ to 194◦F
(80◦ to 90◦C).

Figure 18.

(2) Using a plastic hammer and brass bar,